High Value Manufacturing For The Mega-Shell Large Scale Ceramic Shell Investment Casting Facility At The Advanced Manufacturing Research Centre

先进制造研究中心超大型陶瓷壳熔模铸造设备的高价值制造

• 批准号: 110137
• 金额: $ 1051.85万
• 依托单位: HIGH VALUE MANUFACTURING CATAPULT
• 依托单位国家: 英国
• 项目类别: Centres
• 财政年份: 2013
• 资助国家: 英国
• 起止时间: 2013 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=110137
• 关键词: Value; Manufacturing; Mega; Shell; Large

MEGAshell is a ceramic shell moulding and casting process for very large precision castings. By investing in this capability, AMRC Castings will now be able to produce parts in moulds of up to two metres in diameter and 2.5 metres long, which could weigh more than 2.5 tonnes.The facility will be large enough to make moulds to produce the largest variants of aero engine intercases, up to 500kg, and structural aerospace components, with dimensional accuracy and surface finish comparable to investment casting. AMRC Castings is the only UK operation able to produce a ceramic shell of this size. It demonstrates the UK’s emergence into what has been a tightly controlled market and provides the opportunity to be competitive on a global stage.In addition to the benefit for the aerospace industry, there is also significant value for other industries. This has already been demonstrated in the nuclear sector, delivering significant cost reductions. By using its Replicast® and MEGAshell® technologies, AMRC Castings has been able to create a single ceramic mould to cast a highly dimensionally accurate, one piece stainless steel frame, with a superior surface finish, to fit on top of nuclear waste storage vessels. Currently, the frames are fabricated from 30 separate pieces of stainless steel – a costly and complex process, involving welding and detailed inspection of each joint. The project for Sellafield, aims to develop the UK’s civil nuclear manufacturing supply chain, and help UK companies win work in the industry at home and abroad:“We believe we can reduce the cost of the box by a sixth and, given the number of boxes, this could total up to £150m”, says Richard Gould, AMRC Castings’ Commercial Manager.

MEGA壳体是一种陶瓷壳体造型和铸造工艺，适用于超大型精密铸件。通过对这一能力的投资，AMRC铸件现在将能够在直径最大2米、长2.5米的模具中生产零件，这些模具的重量可能超过2.5吨。该工厂将足够大，可以生产最大型号的航空发动机箱体，重达500公斤，以及结构航空部件，其尺寸精度和表面光洁度可与熔模铸造相媲美。AMRC铸造厂是唯一一家能够生产这种尺寸的陶瓷外壳的英国工厂。它展示了英国进入了一个一直受到严格控制的市场，并提供了在全球舞台上具有竞争力的机会。除了对航空航天行业的好处外，它对其他行业也有重大价值。这一点已经在核能部门得到了证明，大大降低了成本。通过使用Replicast®和MEGAShell®技术，AMRC铸件已经能够创建单一陶瓷模具，以铸造尺寸高度精确的一体式不锈钢框架，具有卓越的表面光洁度，适合安装在核废料储存容器的顶部。目前，框架是由30块独立的不锈钢制成的-这是一个昂贵而复杂的过程，涉及焊接和对每个接头的详细检查。Sellafield的这个项目旨在发展英国的民用核能制造供应链，并帮助英国公司在国内外赢得该行业的工作：AMRC铸件商务经理理查德·古尔德表示：“我们相信我们可以将盒子的成本降低六分之一，考虑到盒子的数量，总成本可能高达1.5亿GB。”